SEMBODAI RUKMANI VARATHARAJAN ENGINEERING COLLEGE

SEMBODAI 614809

DEPARTMENT OF CIVIL ENGINEERING

CE 2045 PREFABRICATED STRUCTURES

PREPARED BY,
KESAVAN.K
AP/CIVIL/SRVEC

UNIT I: INTRODUCTION
PREFABRICATION
NEED OF PREFABRICATION
MATERIALS
MODULAR CO-ORDINATIONS
STANDARIZATION
SYSTEMS
PRODUCTION
TRANSPORTATION
ERECTION

PREFABRICATION / PRECAST / PREMOULDING

Definition:
Prefabricated

building is the completely assembled

and erected building of which the structural parts
consist of prefabricated materials.

It

can apply to any shape and specifications in off site.

Manufacture

in a factory or other manufacturing site,

and transporting to the location.

Disuniting

structures and conventional structures.

TYPES OF PREFABRICATION
Small

prefabrication,
Medium prefabrication,
Large prefabrication,
Cast-insitu-prefabrication,
Off site prefabrication,
Partial prefabrication,
Total prefabrication.

PRINCIPLES / AIM / OBJECTIVE

To

effect economy in cost.

To improve quality.
To speed up construction since no curing is necessary.
To use locally available materials.
Short duration project.

ADVANTAGES
Construction time is reduced,
Project completed very soon,
Earlier return on investment for obtained from the building,
Quality control can be is easily achieved,
Economy,
Independence of climatic conditions,
Less workers needed,
Work done with better technology,
Interruption in connection can be omitted,
On site construction and condition is minimized,
Less waste may occur.

MATERIALS OF CONSTRUCTION
Materials like concrete,steel,treated wood,aluminum etc
Special characteristics while choosing materials
Easy available
Economy
Easy workability
Light weight
Durability

MODULAR CO-ORDINATION

Modular coordination is a concept of coordination of

dimension and space in which building components
are positioned in terms of MODULE(M)

1M= 100mm

DIFFERENT MODULAR CO-ORDINATION

Modular co-ordination

Basic module

Sub module

M, M

Multiple module

Horizontal
3m,6m,12m,60m

Vertical
3m,6m

DIMENSIONS OF Prefab. COMPONENTS

FLOORING AND ROOFING:

Length- multiple of 3M
Width multiple of 1 M
Thickness multiple of M/4

BEAMS:
Length multiple of 3M
Width multiple of M/4
Depth multiple of M/4

COLUMN:
Height multiple of 1M for ht up to 2.8M and ht above
28M is multiple of 2M
Lateral dimension- multiple of M/4

WALL:
Thickness multiple of M/4

STAIRCASE:
Width multiple of 1M

LINTELS:
Length multiple of 1M
Width multiple of M/4
Depth multiple of M/4
o

SUNSHADE:
Length multiple of 1M
Projection- multiple of 1M
Height

and width of openings M 100 mm.

STANDARIZATION

Factors influencing :
Reducing the number of joints by using largest type of
elements.
To select the suitable type of member for each element from
the point of production, assembly ,economy, etc..
To limit the size there by reducing the transportation and by
reducing the over all weight.

Advantages:
Easier in design,
Easier in manufacture,
Makes repeated use of specified equipments in erection and
completion easier and quicker.

PRECAST UNIT

Building components depend upon the specifications,

Small units: (Plan area) < 2m
Large units: (Plan area) > 2m

Size

Light weight: 300N (Upto 300N)

Medium weight: 5000 N
Weight
Heavy weight: More than 5000N

PRECAST UNIT
Precast unit:
Foundation element,
Column element,
Beam element,
Wall panels,
Slab panels.

DIMENSIONAL TOLERANCE
Uneconomical to maintain stir degree of accuracy as listed on
a plan () acceptance.
Types:
Manufacturing tolerance (T),
Setting out of tolerance (P1),
Erection of tolerance (P2).

PRODUCTION

Method for manufacture of PF components:

Factory prefabrication / Off site construction,
Site prefabrication.

FACTORY PREFABRICATION
(Wall, Roof, Slab, Beam, Column)
Done in centrally located plant,
High level of mechanization,
Concreting (Mix design) {C:S:A}-[A:W]
Preparation of mould,
Reinforcement placing with cover,
Pouring,
Compaction / Vibration,
Curing with suitable,
Demoulding,
Finishing.
Transporting to site.

SITE PREFABRICATION
Manufactured at site or near the site.
Normally done in open space with local labours.
Reduction of transport cost.

Draw Backs:
Not suitable for high degree mechanization.
Continuity of work is not available.

PROCESS INVOLVED

Main process,

Auxiliary process,

Subsidiary process.

MAIN PROCESS
Assembling Moulds,
Placing Reinforcements In Position,
Fixing Of Tubes If Necessary,
Batching,
Mixing,
Pouring Of Concrete,
Compacting / Vibrating,
Demoulding,
Curing,
Finishing.

AUXILIARY PROCESS

It s necessary for successful completion of process covered by

main process.

Testing products.

SUBSIDIARY PROCESS

Storage of materials.

Transport of cement and aggregate.

Transporting and stacking the precast elements.

Repairs and maintenance of tools, machines etc

PRODUCTION TECHNIQUES

Various methods of manufacture of precast unit can be broadly

classified in two methods;
PF

Stand

method,

Flow

method / Belt conveyer method,

Aggregate

method.

STAND METHOD
In this method, the prefabrication mature where they are
moulded while the production teams moves to
successive stands.
The bed on with prefabricates are cast may be fixed or
movable.
Tilting forms are often used and in this method steam
curing is generally done.
Moulds remain stationary at factory.
Various elements required for work is casted in factory
itself and then transported to site.

FLOW (or) BELT CONVEYER METHOD

Precast unit under consideration is in movement according to

the various process involved in it.

Moulds are transported to site for required elements.

The whole production is split up in to series operations carried

out at separate successive and permanent points served by
specialized teams.

The movement of the mould or prefabricate one point to other

vary by means of conveyor belt trolleys.

AGGREGATE METHOD

In the aggregate method, aggregate describes large

complex permanently installed machines &
mechanical appliances which carry out most of the
separate operations involved in the casting of the
concrete composition.
The stand is operated by a permanent team & the only
move the prefabricate makes is to the maturing point.

TRANSPORTATION

Transportation of precast elements inside the factory and to the

site is based on not only economy but also design aspect to
avoid jerk as it s placed in final position.

Inside the factory:

Its based on method of production selected for manufacture.

TRANSPORTATION from FACTORY to SITE

It s planed based on traffic rules.

Size is restricted by the availability of suitable transport

equipment's such as tractor cum trailer.

While transporting through wagons, trucks , bullock,etc

care should be taken such that excessive cantilever is avoided.

Also care should be seen at sharp bends and uneven roads.

Site

Factory

HOISTING PROCESS

Factors to be considered:
Precast element position
Crane capacity
Crane rotation radius
Cleaning of elements and site for erection

Crane
Truck
PF

TYPE OF CRANES
Stationary erection:
Guyed derrick
Climbing carne
Tower crane with fixed base
Cranes on rails:
Portal crane
Tower crane
Mobile crane moving on ground:
Truck mounted
Crawler mounted

Crane
Truck
PF

SPECIAL CRANES
o
o
o
o
o

Truck cranes
Gantry cranes
Mast cranes
Derrick cranes
Twinned mast cranes

H
Crane
Truck

Truck cranes:
lift mortar and upper part.
Weight 31.80 T
Max height of hoisting hook 36.60 m
Rotation - 360

PF

Gantry cranes:
Operation of manufacturing and stored area.
Capacity 5 T, Weight 4.5 T
Max height of hoisting hook 11 m
Mast height 10.9 m operating is 20 T
Space between mast and crane 7.8 m
Derrick cranes:
Highly efficient lifter, It stable or movable.
Capacity 20, 30 T
Twinned mast cranes:
Great height users.
Two crane capacity: 35-70 T
Min.workers: 16
Time: 1-2 days (Difficult higher structures)

STATIONARY CRANES

Guyed derrick:
Used on framed buildings for erection of floor panel ,columns.
Lighter in weight.
Can be shifted from floor to floor operating from an erected
floor.
Climbing crane:

Tall building over 20storeys are constructed this type crane is used.
Horizontal jib and balancing counter weight is placed on top of
shaft.
It operates around 360 degree and can be lifted up to new position
as budged goes on completion and dismantled.
This is used in longest areas.

Tower crane with fixed base:

Places were rail mounted and climbing cranes are not possible
tower cranes can be installed.
These cranes are fixed at base and braced horizontally to the
building portion already completed as building go up ,the
vertical mast can be hoisted up by special hydraulic jack.
CRANES ON RAIL:

Portal cranes:
In storage yards and in buildings where the travel distance is
short portal crane is used.
Consist of two vertical legs and horizontal beam.
Travelling trolley is attached to bottom flange of beam that
carries load horizontally.
It is very stable.

MOBILE CRANES MOVING ON GROUND

Truck mounted crane:

For quick movements from place to place cranes are
mounted on track with operating cabin and separate chassis.
Chassis will have generator and motor.
Before operating the crane with loads,crane is taken off
from pneumatic tyres and load transferred to the ground by
simple hydraulic legs.
CRAWLER MOUNTED CRANES

It s used in excavation ,dredging and material handling.

Should be used on a hard and compacted soil.
On loose soil it is difficult to move the crane with load
It can operate 360 degree.

ERECTION / HOISTING OF COLUMN

ERECTION / HOISTING OF BEAM

Thank you
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